Yes, they connect to any LoRaWAN or MQTT infrastructure (Kerlink, Cisco, Milesight, MultiTech, etc.) for flexible integration with existing SCADA systems.
Refinery Pump Vibration Monitoring (Predictive Maintenance & Reliability) — ATEX
Reduces unplanned shutdowns, increases reliability
Vibration
Quick Overview
| Problem | Pumps are among the most critical and failure-prone assets in refineries. Bearing wear, cavitation, misalignment, or imbalance often develop silently, leading to unplanned shutdowns, safety incidents, and production losses in ATEX-classified areas. |
| Solution | SENSAiO’s ATEX-certified vibration sensors provide continuous, wireless monitoring of refinery pumps, detecting early mechanical degradation and enabling predictive maintenance strategies. |
| Value | Reduced unplanned shutdowns • Extended pump lifetime • Lower maintenance OPEX • Improved HSE performance |
| ATEX | Zones 0–2 • Ex ia IIC T4 Gb certified vibration sensors |
The Operational Challenge
Refineries rely on hundreds of centrifugal and positive displacement pumps for:
- Feedstock transfer
- Product circulation
- Cooling and utility services
- Chemical injection and blending
These pumps operate continuously under harsh conditions involving:
- High temperatures and pressures
- Corrosive or abrasive fluids
- Variable flow regimes
Common pump failure modes include:
- Bearing degradation
- Shaft misalignment
- Cavitation due to suction issues
- Rotor imbalance
- Seal wear and leakage
Traditional monitoring approaches typically involve:
- Periodic handheld vibration measurements
- Manual inspection during scheduled shutdowns
- Reactive maintenance after alarms or failures
These methods provide snapshots, not continuous insight, and often detect issues too late to avoid downtime.
Why Continuous Vibration Monitoring Matters
Vibration signatures are among the earliest indicators of rotating equipment degradation.
Continuous monitoring enables operators to:
- Detect bearing wear weeks or months before failure
- Identify cavitation through high-frequency vibration patterns
- Monitor imbalance and misalignment trends
- Correlate vibration changes with operating conditions
Early detection allows maintenance teams to plan interventions during scheduled outages, rather than responding to emergency failures. In ATEX environments, reducing manual inspection also significantly lowers personnel exposure.
SENSAiO Solution
SENSAiO delivers a wireless, intrinsically safe vibration monitoring solution tailored for refinery pump applications.
Core Components
Vibration Sensor (ATEX Ex ia IIC T4 Gb)
Measures acceleration, velocity, and frequency spectra to identify mechanical faults.
Wireless Communication
Supports LoRaWAN, Modbus, and MQTT, enabling integration with refinery SCADA and maintenance systems.
Installation & Power
Battery-powered, magnetic or bolted installation directly on pump housings or bearing caps.
Operational Benefits
- Early detection of pump degradation
- Reduced risk of catastrophic pump failure
- Optimised maintenance planning
- Improved equipment reliability and availability
Results and ROI
ATEX Compliance and Safety
All vibration sensors for refinery pump monitoring comply with:
- Ex II 2 G Ex ia IIC T4 Gb (Zones 0–2)
- IECEx certification
- ATEX Directive 2014/34/EU
The intrinsically safe design allows installation on live equipment without shutdown, supporting safe operation in explosive atmospheres.
Integration and compatibility
| Protocols | LoRaWAN, Modbus RTU/TCP, MQTT, REST API |
| Systems | SCADA, CMMS, asset management platforms |
| Vendors | Honeywell, ABB, Emerson, Schneider |
| Cybersecurity | AES-128 encrypted communication with secure transport |
FAQ - Common Questions
Are Sensa.io sensors compatible with any gateway or network?
What ATEX certifications apply to Sensa.io devices?
All hazardous-area models are certified Ex II 2 G Ex ia IIC T4 Gb and IECEx approved for Zones 0–2.
What is the typical battery life?
Up to 10 years at 15-minute intervals, depending on signal strength and environment.
How are the sensors integrated into existing systems?
Through standard protocols — LoRaWAN, Modbus, MQTT, REST API — no proprietary middleware needed.
How does predictive maintenance reduce OPEX?
Early anomaly detection reduces emergency interventions by 30–40 %, extends equipment life and lowers energy costs.
What does the Sensa.io Valve Position Sensor actually measure?
The device detects real-time valve position states—open, closed, or intermediate—with high accuracy. It continuously sends this information wirelessly to your monitoring dashboard.
Can this sensor detect partial valve movement or stuck valves?
Yes. The sensor identifies irregular patterns such as partial movement, delayed response, or stuck valves, enabling early maintenance before failure occurs.
Is this sensor suitable for manual, motorized, and actuated valves?
Yes. It supports a wide range of valve types including ball, gate, butterfly, actuator-driven, and manual valves.
How fast does it update the valve position?
You can configure the reporting interval—from seconds to minutes—depending on your operational and battery needs.
How long does installation take?
Most installations take under 10 minutes. The sensor mounts using brackets or clamps without modifying existing valves.
Explore Our Sensors
Valve position
The Sensa iO Valve Position Sensor provides real-time open/close feedback for manual and automated valves in oil & gas, chemical, and hydrogen operations.
Pressure
A rugged, industrial-grade pressure sensor designed for high-demand oil & gas applications. Provides continuous gas and liquid pressure monitoring, with ATEX intrinsic safety, IP67 housing, and LoRaWAN® connectivity.
Temperature
Sensa iO’s temperature sensor delivers precise temperature data for process lines, steam systems, heat exchangers, and storage assets.
Differential Pressure (ΔP)
A compact DP solution using dual synchronized pressure inputs to deliver accurate differential pressure data for filters, heat exchangers, separators, and manifolds.
Vibration
A high-resolution vibration sensor built for predictive maintenance of pumps, motors, compressors, and rotating equipment.
Acoustic
The Sensa iO acoustic sensor identifies ultrasonic leak signatures, gas escape, steam trap failures, and flare noise anomalies.
Trusted by a Worldwide Network
With partners in over 20 countries, Sensa IO delivers rugged sensor solutions to the toughest environments — everywhere.
